Modular scaffold board

ABSTRACT

A modular scaffold board comprising: a plurality of board members of different lengths; and at least one joining member, for joining the board members in an end-to-end fashion. A kit of parts comprising a plurality of board members of different lengths, joining members and end parts for forming modular scaffold boards in a wide variety of lengths is also described.

The present invention relates to a modular scaffold board which can be used as part of a temporary scaffold structure for supporting people and materials in the construction or repair of buildings and other large structures.

Scaffolding systems ordinarily comprise a series of tubes, couplers and boards to provide a stable structure from which tradesmen can work. The tubes form the basic framework of the scaffold structure, linked together by couplers. Tubes are usually formed from steel or aluminium but composite materials are sometimes used (in particular if there is a risk from electrical cables).

Boards are used to provide a supporting surface to support scaffold users and materials. Typically, boards are made from seasoned wood. Scaffold boards come in standard thicknesses of 38 mm (about 1.5 inches), 50 mm (about 2 inches) and 63 mm (about 2.5 inches), have a width of 225 mm (about 9 inches) and may be up to 3.9 m (about 13 feet) in length. In addition to wooden boards, steel, aluminium and polymer composite boards may be used.

In order to provide scaffolding that fits the particular building or structure under construction, repair, etc, full length scaffold boards are cut into shorter lengths for individual projects. This results in numerous, unrequired, offcuts. These offcuts are then either discarded or stored in the hope they may be required on another project at some point in the future. The cut length will also be stored at the end of the project with the same hope that it may be required again.

In practice, however, it is often inefficient to use cut lengths from previous projects. A selection of lengths may be transported to the site of a project speculatively, many of which will not be suitable. Time and resources are therefore wasted, firstly, on transporting the cut lengths, and secondly, on finding and selecting a suitable length board. Consequently, it is often more practical to transport only full length boards and cut these down to size on site. This leaves many cut scaffold boards unused, in storage.

In storage, large quantities of cut boards are often left out in the open for months on end, while further full length boards are cut down into different required lengths and will eventually add to the stock pile. Unused scaffold boards, particularly those made from wood, have a limited life span when stored for long periods out in the open, especially if spacing timbers are not used between each length of board to allow the air to circulate, which is often the case. Therefore, many cut boards become unusable after a period of time so are wasted.

Storing the various length scaffold boards also takes a considerable amount of time and resources. This is because it is necessary to sort the returned boards by size in order to store them in the correct location, with others of the same length. Further, each stored scaffold board needs to be visually inspected for signs of weather deterioration before being allowed back into the work space. This requires large areas that can be easily accessed, which is costly.

One practice in the scaffolding industry known as “notching” involves removing a small section to create a recess, a “notch”, at an edge of a board in order to fit round an obstacle such as pipe-work or steel-work. However, once notched, a board is usually rendered unusable. Therefore, either an entire board is lost or the board may be cut into smaller lengths, adding to the problems discussed above.

It is an aim of the present invention to at least partially address some of the issues above.

According to a first aspect of the invention, there is provided a modular scaffold board comprising: a plurality of board members of different lengths; and at least one joining member, for joining the board members in an end-to-end fashion.

Said at least one joining member may be a separate component from the board members. The joining member may comprise a male connecting member at each end connecting with a respective female connecting member of the board members it connects.

In another arrangement, said at least one joining member may comprise a male connecting part at one end connecting with a female connecting part of one board member and a female connecting part at the other end connecting to a male connecting part of another board member.

In a preferred embodiment, each board member has a male connecting part at one end and a female connecting part at the other end and the joining member also has a male connecting part at one end and a female connecting part at the other end.

Each board member may have a joining member integrally formed therewith. The joining member may comprises a male connecting part at one end of the board member which connects with a female connecting part of another board member.

Preferably, the modular scaffold board comprises an end cap at each end thereof. One end cap may have a male connecting part connected to a female connecting part of a board member and the other end cap may have a female connecting part connected to a male connecting part of another board member.

According to a second aspect of the present invention, there is provided a kit of parts for a modular scaffold board, the kit of parts comprising: a plurality of board members of different lengths; and at least one joining member, for joining the board members in an end-to-end fashion.

The kit of parts may comprise: a plurality of boards members including board members of at least two different lengths in which the joining member comprises a male connecting part at one end and a female connecting part at the other end integrally formed therewith for joining the board members in an end-to-end fashion.

The kit of parts may also comprise a plurality of end caps for fitting to the ends of the modular scaffold board(s).

Preferably, the kit of parts comprises a plurality of boards members including board members of at least two different lengths, each board member comprising a male connecting part at one end and a female connecting part at the other end, and a plurality of end caps for fitting to the ends of the modular scaffold board(s).

In a first preferred arrangement, the kit of parts comprises a plurality of board members of a first length 12 L and a plurality of board members of a second length 24 L, together with a plurality of end caps of length 2 L and/or 4 L, whereby modular boards can be assembled in a wide variety of lengths in increments of 2 L.

The kit of parts may also comprise a plurality of third board members of a third length 36 L.

The kit of parts may also comprise a plurality of fourth board members or joining members comprising a male connecting part at one end and a female connecting part at the other end, the male and/or female connecting parts thereof being adapted so that the fourth board member or joining member can be connected only between another board member and an end cap.

Said fourth board members or joining members may have a length of 4 L.

In a preferred arrangement L=1 inch (2.54 cm) so board members are provided in 1 foot, 2 foot and/or in 3 foot lengths (about 30 cm, 61 cm and 91 cm, respectively)

The board members preferably have a substantially rectangular cross-section. The board members may have an upper face, a lower face and two side faces, the side faces being substantially planar so they can abut against or be positioned close to side faces of one of more adjacent modular board members.

In a preferred embodiment, the upper face may be substantially planar and the lower face has an open, concave or recessed form.

The male and female connecting parts of the joining member are preferably configured to provide a connection between board members which gives the modular scaffold board stability under forces exerted in a direction perpendicular to the direction of engagement of the male and female connecting parts.

Said connection is preferably able to support at least the weight of a person standing thereon whereby, when a modular board is supported by a plurality of transoms spaced apart by a minimum recommended spacing S, board members having a length less than S do not necessarily have to be supported by a transom.

The modular scaffold board or kit of parts may further comprising a locking mechanism for releasably locking the board members and the joining member in the joined state.

The locking mechanism may comprise mutually engageable male and female components at respective ends of each board member and a locking member moveable between an open position in which it permits said male and female components can be engaged and disengaged from each other and a locked position in which it inhibits disengagement of the male and female components.

The locking member may be a separate component which is rotatable relative to the board member between said locked and unlocked positions.

In a preferred embodiment, the locking member is rotatable about an axis substantially perpendicular to a major face of the board member.

The modular scaffold board or kit of parts may be formed substantially of a plastics material and may be formed by injection moulding.

According to a third aspect of the present invention there is provided a method of forming a modular scaffold board, the method comprising the steps of: selecting a plurality of board members from a group of board members including board members of different lengths; joining the plurality of board members in an end-to-end fashion with at least one joining member.

The method may further comprise the step of: capping at least one non-joined end of the board members with an end-cap selected from a group of end-caps including end-caps of different lengths.

The assembled modular scaffold board is preferably arranged to be supported by transoms positioned beneath the board.

Preferably, the modular scaffold board is arranged to be used alongside conventional wooden scaffold boards having substantially the same cross-sectional dimensions.

According to a fourth aspect of the present invention, there is provided a board member for the modular scaffold board according to the first aspect, comprising: a substantially cuboidal member having a substantially rectangular cross-section in a transverse plane; at least one hollow intrusion, extending in a longitudinal direction perpendicular to the transverse plane, from one end face of the cuboidal member, forming a female connecting part.

According to a fifth aspect of the present invention, there is provided a joining member for the modular scaffold board according to the first aspect, comprising: a substantially cuboidal member having a substantially rectangular cross-section in a transverse plane; at least one protrusion, extending in a longitudinal direction perpendicular to the transverse plane, from each end face of the substantially cuboidal member, forming a male connecting part.

The joining member may further comprise: at least one elastic locking member at each end, configured to engage with an engaging portion of a board member.

According to a sixth aspect of the present invention, there is provided an end-cap for the modular scaffold board according to the first aspect, comprising: a substantially cuboidal member having a substantially rectangular cross-section in a transverse plane; at least one protrusion, extending in a longitudinal direction perpendicular to the transverse plane, from one end face of the substantially cuboidal member, forming a male connecting part.

The end cap may further comprise: at least one elastic locking member configured to engage with an engaging portion of a detachable board member.

The board members and joining members may be mirror symmetric in three orthogonal planes, corresponding to planes perpendicular to length, width and thickness directions of the modular scaffold board.

The end-cap may be mirror symmetric in two orthogonal planes, corresponding to planes perpendicular to width and thickness directions of the modular scaffold board.

With the present invention, a modular scaffold board of almost any desired length, can be constructed from a number of different length board members and joining members. This eliminates the need to cut boards to a desired length. This in turn increases the efficiency with which scaffolding can be erected, reduces wastage and improves storage operations. Further, only individual board members need be notched, therefore a small section can be discarded as opposed to a whole board, thus reducing waste.

As indicated above, in a preferred arrangement, most or all of the board members may be provided in two relatively short lengths, e.g. 1 ft (about 30 cm) and 2 ft (about 61 cm) board members, from which a wide range of board lengths can be constructed. The end caps are also preferably provided in a range of lengths, e.g. 1 inch (about 2.5 cm), 3 inches (about 7.6 cm) and 5 inches (about 12.7 cm), so that it is possible to construct board lengths of almost any desired lengths.

A preferred kit of parts comprising a plurality of board lengths of two relatively short lengths, a plurality of joining members and a plurality of end caps of different sizes is thus sufficient for the majority of applications and can be dis-assembled for re-use in other applications with little or no wastage. The use of a kit of parts comprising this small number of different components also greatly simplifies, storage and transportation of the components and is much more efficient to organise and use.

Further, because the board is made up of modular parts, which are lighter, easier to carry and easier to manoeuvre than full length boards, accidents and work place injuries can be reduced, thus improving safety. Further still, because the board members are joined end-to-end, there are fewer trip hazards compared to regular boards which are not joined. Also, modular parts can be carried to high or difficult-to-reach platforms more easily than full length boards, thus improving accessibility. When short boards are required to make up the platform length they tend to become easily displaced due to their weight and length unless they are secured to the scaffold, so by being able to join smaller board members together, not only are trip hazards reduced, also the possibility of movement of individual boards is greatly reduced.

Other preferred and optional features of the invention will be apparent from the following description and from the subsidiary claims of the specification.

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which corresponding reference symbols indicate corresponding parts, and in which:

FIG. 1A shows a perspective view of a first embodiment of a modular scaffold board.

FIG. 1B shows an exploded view of the modular scaffold board in FIG. 1A.

FIG. 2A shows a perspective view of another modular scaffold board.

FIG. 2B shows an exploded view of the modular scaffold board in FIG. 2B

FIG. 3 shows a perspective view of a joining member used in the first embodiment.

FIG. 4 shows a perspective view of an end-cap used in the first embodiment.

FIG. 5 shows a perspective view of an enlarged male connecting part of the joining member.

FIG. 6 shows a perspective view of an enlarged elastic locking member of the joining member.

FIG. 7A shows a perspective view of a board member of a second embodiment of a modular scaffold board.

FIG. 7B shows a perspective view of a locking member used with the board member of FIG. 7A.

FIG. 8A and 8B show a plan view and an end view, respectively, of the board member of FIG. 7A.

FIG. 9A and 9B show a bottom view and an end view (from the other end), respectively, of the board member of FIG. 7A.

FIG. 10A is a perspective exploded view of the locking member of FIG. 7B and part of the board member of FIG. 7A.

FIG. 10A is a perspective view showing the locking member installed within said board member, and FIG. 10C is a sectional view thereof.

FIGS. 11A, 12A and 13A are perspective views of a joining member of the second embodiment of a board member illustrating operation of the locking member—the board member in which the locking member is mounted (in the manner shown in FIG. 10) being omitted for clarity.

FIGS. 11B, 12B and 13B show plan views of the position of the locking member in relation to the board member in the steps shown in FIGS. 11A, 12A and 13A, respectively.

FIG. 11C is a side view of the locking member in the position shown in FIG. 11A and FIG. 13C is a side view of the locking member in the position shown in FIG. 13A.

FIG. 14A is an exploded perspective view of two board members of the second embodiment prior to being joined together.

FIG. 14B is a perspective view of the two board members of FIG. 14A once joined together.

FIG. 15 is an exploded perspective view of an end piece and a board member of the second embodiment prior to being joined together.

FIG. 16 is a perspective view of a shorter board member of the second embodiment.

FIG. 1A is a drawing of a modular scaffold board illustrative of a modular scaffold board according to a first embodiment of the present invention. FIG. 1 also indicates a length direction 1, width direction w and thickness direction t, of the modular scaffold board and its modular parts, used in the following detailed description. The modular scaffold board comprises a plurality of board members 1 of different lengths (in FIG. 1A, two boards are used with lengths L1 and L2) and at least one joining member 2, joining the board members 1 in an end-to-end fashion (i.e. in a length direction 1). FIG. 1B shows an exploded view of the modular scaffold board of FIG. 1A.

Any number of board members 1 may be used to form a modular scaffold board of a desired total length, L. Any number of different length board members 1 may be used. By using different length board members 1, modular scaffold boards of different lengths can be constructed. The lengths of the joining members 2, if multiple joining members 2 are used, may also be different. However, it is preferable that these are of a single length. This is because it is then only necessary to make a single length available for use, which prevents any wasted time in selecting the optimal length joining member 2.

The modular scaffold board may also include one or more end-caps 3 at non-joined ends of the board members 1. The end caps may be the same or different lengths. Providing end-caps 3 in a plurality of lengths allows the user to create modular scaffold boards in a wider variety of total lengths.

Most preferably, board members 1 may be provided in a finite number of lengths, for example, a plurality of lengths selected from 1 ft, 2 ft or 3 ft lengths. The end-caps 3 may also be provided in a finite number of lengths, for example, a plurality of lengths selected from 1 inch, 2 inch, 3 inch, 4 inch, 5 inch or 6 inch lengths.

The modular scaffold board of the invention may be constructed from a kit of parts. The kit of parts includes a plurality of board members, at least one joining member and may include one or more end-caps. Preferably the kit of parts includes a plurality of board members in 1 ft and 2 ft lengths, a plurality of identical joining members and a plurality of end-caps in 1 inch, 3 inch and 5 inch lengths. End-caps with these lengths can combine to create additional lengths in 2 inch increments (2 inch, 4 inch, 6 inch, 8 inch and 10 inch lengths). This combination of different lengths provides an adequate range of options for most applications, with an easily manageable number of components.

It should be noted that the modular scaffold board of the present invention as a whole (i.e. multiple board members 1 connected by joining members 2 with optional end-caps 3) preferably has a strength equal to, or surpassing, a similar length wooden board. Therefore, the same standard governing supporting wooden boards will apply to the modular scaffold board. This standard is that a minimum of three supports are provided to any length board (or modular scaffold board), with no more than 1.2 m between supports. Alternatively, lower specification modular scaffold boards may be provided which, for example, require supports at 0.9 m intervals.

The width and thickness of the modular scaffold board is preferably the same as standard wooden boards, namely 9 inches wide and 1.5 inches (38 mm) thick. This means that the modular scaffold board of the present invention is suitable to be used in combination with wooden boards so as to provide even greater versatility.

An outer surface of a joining member 2 may form an outer surface of the modular scaffold board, as illustrated in FIG. 1A. The board members 1 and joining members 2 may form a contiguous surface and a top and/or side face of the modular scaffold board. Similarly, an outer surface of an end-cap 3 may form an outer surface of the modular scaffold board, such that the board members 1 and end-caps 3 may form a contiguous surface and a top and/or side face of the modular scaffold board. Additionally, an end-face of an end-cap 3 forms an end-face of the modular scaffold board. This end-face is preferably flat.

The modular scaffold board preferably has a substantially homogenous cross-sectional shape over its full length. In particular, it is preferable that the thickness and/or width of the modular scaffold board is homogenous over its entire length. This improves safety and improves ease of use.

The board members 1 (as shown in FIGS. 1A-2B) may comprise a substantially cuboidal member 11 having a substantially rectangular cross-section in a transverse plane. The joining members 2 and end-caps 3 may have a similar basic structure. The joining member 2 (as shown in FIG. 3) may comprise a substantially cuboidal member 21 having a substantially rectangular cross-section in a transverse plane. The end-cap 3 (as shown in FIG. 4) may comprise a substantially cuboidal member 31 having a substantially rectangular cross-section in a transverse plane. The substantially cuboidal members of each of the board members 1, joining members 2 and end-caps 3 forming a modular scaffold board, preferably have the same thickness t) (in a direction perpendicular to a supporting surface of the board member) and width w) (in a direction parallel to a supporting surface of the board member), but may differ in their lengths l). Outer surfaces of the substantially cuboidal members of the board members 1, joining members 2 and end-caps 3 may form the outer surfaces of the modular scaffold board.

As mentioned, board members 1 of the present invention, are configured to be joined end-to-end (i.e. in a length direction 1) by a joining member 2, as shown in FIGS. 1A and 2A. One board member 1 is joined to each end of the joining member 2. The board members may also be configured to be joined with an end-cap 3, as shown in FIG. 2A. Joining a board member 1 to a joining member 2 or an end-cap 3 can be done in any number of ways, some examples of which are described below. These examples are described with reference to the joining member 2, however the same applies to the end-cap 3.

The board members 1 may each include a female connecting part 4 and the joining member 2 (or end-cap 3) may include a male connecting part 5. At least two male connecting parts 5 are provided on the joining member at opposite end faces of the joining member 2. At least one male connecting part 5 is provided on the end-cap 3 at one end face. The board members 1 may also include female connecting parts 4 at each end. The board members 1 may be joined to the joining member 2 (or end-cap 3) by engagement of the male connecting parts 5 with the female connecting parts 4. The engagement of the male connecting parts 5 of the joining member 2 (or end-cap 3) and female connecting parts 4 of the board member 1 gives the modular scaffold board stability under force exerted in a direction perpendicular to direction of engagement of the male connecting parts 5 and female connecting parts 4 (the length direction 1), for example from the weight of a person or materials on the modular scaffold board. In order to maximise this stability, it is preferable that the engagement length (i.e. the overlapping distance between the male connecting parts 5 and female connecting parts 4) is sufficiently long. However, if the engagement length is too large, this may result in difficulty in the construction of the modular scaffold board and/or increase the size and weight of the joining member 2. Therefore, it is preferable that the engagement length is between about 1 and 6 inches. More preferably, the engagement length should be between about 2 and 4 inches. Preferably still, the engagement length should be about 3 inches.

The male connecting parts 5 and female connecting parts 4 may have a variety of complementary shapes for engaging with each other but should provide a secure, tight connection between the board members, be of sufficient strength and be relatively easy to assemble and disassemble.

Preferably, the female connecting parts 4 should have a substantially rectangular cross-sectional shape in a plane perpendicular to the direction of engagement (transverse plane). Preferably, the cross sectional area is homogenous over the engagement length. The female connecting parts 4 may be of any length. Preferably, female connecting parts 4 at either end of the board member 1 form a single hollow intrusion through the entire length of the board member 1, extending in a longitudinal direction (length direction 1), perpendicular to the transverse plane of the board member 1. Preferably, this hollow intrusion has a homogenous rectangular cross-section as shown in FIGS. 1A-2B. In the embodiment shown in FIGS. 1A-2B, each female connecting part 4 is formed from a rectangular, hollow tube through the board member 1. A board member 1 with these features, namely a board member 1 with a uniform cross-section, is ideally suited to being formed by an extrusion method, making large scale manufacturing easy. Therefore materials suitable for extrusion, such as plastics and some metals, are preferably used for the board member, this will be discussed in more detail later.

According to an embodiment, male connecting parts 5 are formed by at least one protrusion, extending in a longitudinal direction (length direction 1) perpendicular to the transverse plane of the joining member 2 (or end-cap 3), from each end face (or one end face, in the case of an end-cap 3) of a substantially cuboidal member of the joining member 2 (or end-cap 3). Preferably, the male connecting parts 5 should have a substantially rectangular cross-sectional shape in a plane perpendicular to the direction of engagement (transverse plane). The cross-sectional area may be homogenous over the entire engagement length. However, preferably, the cross-sectional area is largest at a proximal end 51 and smallest at a distal end 52 of the male connecting part 5, so as to assist the construction of the modular scaffold board. Preferably, the thickness of the male connecting part 5 changes in at least a portion of the male connecting part 5 creating a different cross-sectional area, the width of each male connecting part 5 is preferably uniform.

In the embodiment shown in FIG. 5, a first, proximal-most portion 53 of the male connecting part 5 has a relatively large homogenous cross-sectional shape and area, a second portion 54 of the male connecting part 5 is tapered, a third portion 55 has a relatively small homogenous cross-section and a fourth, distal-most portion 56 is also tapered. In this embodiment, the difference in cross-sectional area is created by changing the thickness of the male connecting parts 5 in the tapered portions. The change in thickness need not be very large to make insertion of the male connecting parts 5 into the female connecting parts 4 easier. A difference greater than 1 mm is sufficient. The difference in thickness at the distal-most tapered portion 56 can be larger than the difference in other tapered portions 54 because this has less influence over the overall fit with the female connecting parts 4.

Any number of male connecting parts 5 may be included at each end of the joining member 2 (or one end of the end-cap 3), for example one, two, three or four male connecting parts 5. At least a corresponding number of female connecting parts 4 should be included at an end of the board member 1.

As shown in FIGS. 1B, 2B, 3 and 4, in one embodiment, four male connecting parts 5 are provided on the joining member 2 and end-cap 3 at each joining face. Four corresponding female connecting parts 4 are provided at both ends of the board member 1. The four male connecting parts 5 and female connecting parts in this embodiment are arranged in a single straight line. Further each male connecting part 5 and female connecting part 4 are identical. Each of the male connecting parts 5 is separated by a gap 50 of sufficient width to accommodate a wall 40 separating each female connecting part 4. Gaps 50 and walls 40 should be provided so as to fit closely, with a small tolerance. This ensures a secure fit between the male connecting parts 5 and the female connecting parts 4. The width of the wall 40 is preferably between 3.5 mm and 4.5 mm. The width of the gaps 50 should be kept to the minimum width permissible to allow functionality. Preferably, the gaps 50 are no more than 0.6 mm wider than the walls 40. In the embodiments shown in the figures, the width of the gaps 50 is 3.6 mm and the width of the walls 40 is 3 mm.

However, the male connecting parts 5 and female connecting parts can take any complementary arrangement, for example they may be formed in two vertically displaced (in the thickness direction t) horizontal lines (in the width direction w). Further the male connecting parts 5 and female connecting parts may not be identical, some may be larger and some smaller, for example.

The modular scaffold board may further comprise a locking mechanism for releasably locking the board members 1 and the joining member 2 (or end-cap 3) in the joined state. Preferably the locking mechanism automatically locks the board members 1 and the joining member 2 (or end-cap 3) in the joined state. However, a manually operable locking mechanism can be used. Any moving parts of the locking mechanism are preferably part of the joining member 2 (or end-cap 3) as opposed to the board member 1. The locking mechanism is preferably confined within the profile of the modular scaffold board, i.e. it does not protrude beyond any outer most surface of the modular scaffold board.

The locking mechanism may comprise an elastic locking member 6 configured to engage with an engaging portion 7 a, for example a snap-fit locking mechanism may be provided. The elastic locking member 6 and engaging portion 7 a may be arranged such that the elastic force produced when the elastic locking member 6 is elastically deformed acts to engage the elastic locking member 6 with the engaging portion 7 a and/or to prevent disengagement. The elastic locking member 6 and engaging portion 7 a are provided on one or other of the joining member 2 (or end-cap 3) and the board member 1. Preferably, the elastic locking member is provided on the joining member 2 (or end-cap 3) and the engaging portion 7 a is provided on the board member 1.

According to an embodiment, the elastic locking members 6 are formed by at least one protrusion, extending in a longitudinal direction (length direction 1) perpendicular to the transverse plane of the joining member 2 (or end-cap 3), from each end face (or one end face, in the case of an end-cap 3) of a substantially cuboidal member of the joining member 2 (or end-cap 3). The elastic locking member 6 may be a cantilever-type member projecting, in the direction of engagement of the board member 1 and the joining member 2 (or end-cap 3), from the joining member 2 (or end-cap 3). The elastic locking member 6 may itself include a projection 61 in a direction parallel to the direction of elastic force produced when the elastic locking member 6 is elastically deformed. The board member 1 may include a corresponding depression or aperture as the engaging portion 7 a of the locking mechanism. In such an example, the depression or aperture is preferably shaped to at least partially conform with the projection 61 of the elastic locking member 6. In such a case, the elastic locking member should be made from a material, and have a thickness, which gives it some elasticity, such as plastic or thin metal. As shown in FIG. 6, the elastic locking member 6 is preferably a substantially flat protrusion of the joining member 2 (or end-cap 3). One face 6F of the elastic locking member 6 includes a projection 61 such as that described above. The projection 61 preferably has a sloped side 61 a toward a distal end of the elastic locking member 6 and a flat side 61 b toward a proximal end of the elastic locking member 6. The elastic locking member 6 may also have a curved, distal-most edge 62 for assisting with the locking action, as shown in FIG. 6.

The board member 1 may include a hollow intrusion 7 for accommodating the elastic locking member 6. The engaging portion 7 a may be formed in an inner wall of the hollow intrusion 7. The hollow intrusion 7 may be one of the female connecting parts 4 described above. The hollow intrusion 7 is preferably separate from the female connecting parts 4 described above. The hollow intrusion 7 may span the full length of the board member 1 so as to form part of a locking mechanism at both ends of the board member 1. The hollow intrusion 7 preferably has a substantially rectangular cross-section in a transverse plane of the board member 1. Such an arrangement is shown in FIGS. 1A-2B and contributes, along with the shape of the female connecting parts 4, to the board member 1 in the embodiments depicted in the figures having a uniform cross-section (excluding the engaging portion 7 a). Therefore, this board member is suitable for manufacturing using an extrusion method. In the embodiment shown in FIGS. 1A-2B, the engaging portion 7 a is in the form of an aperture formed by a through hole. This can be formed in an extruded board member 1 by simply drilling the through hole in a side of the board member 1 at the required position.

When the joining member 2 (or end-cap 3) and board member 1 are engaging, the sloped side 61 a of the projection 61 of the elastic locking member 6 contacts a portion of the board member 1 converting a force in the engagement direction into a force in a perpendicular direction, deforming the elastic locking member 6. As the engagement continues, the elastic locking member 6 maintains its deformed state until the position of the projection 61 of the elastic locking member 6 corresponds to the position of the engaging portion 7 a. The elastic force produced by the elastic locking member 6 acts to engage the projection 61 of the elastic locking member 6 with the engaging portion 7 a. If the joining member 2 (or end-cap 3) and board member 1 are moved in the opposite direction, the flat side 61 b of the projection 61 of the elastic locking member 6 contacts the wall of the engaging portion 7 a so as to prevent separation of the joining member 2 (or end-cap 3) and board member 1. Such an arrangement is referred to as a snap-fit arrangement.

To release the locking mechanism, a force can be applied to deform the elastic locking member 6 and disengage the projection 61 of the elastic locking member 6 and the engaging portion 7 a. Preferably, this force is applied via the engaging portion 7 a by providing a through-hole 7 b, from an outer surface of the board member 1 to the engaging portion 7 a, in a direction parallel to the direction of engagement of the projection 61 of the elastic locking member 6 and the engaging portion 7 a. The through-hole 7 b may be formed continuously with the engaging portion 7 a. The through-hole 7 b and engaging portion 7 a are preferably circular. Providing the engaging portion 7 a in such a manner can be done easily, by drilling a through hole into the board member 1, as discussed above. The material of the board member can also be selected for this purpose i.e. a material that can be easily drilled such as plastic.

The through-hole 7 b is preferably provided in a side surface of the board member 1. The engaging portion 7 a is therefore preferably provided in a side wall of the board member 1. The elastic locking member 6 is therefore preferably arranged to be elastically deformable in a direction perpendicular to a side surface of the board member 1 and therefore the joining member 2 (or end-cap 3), namely a width direction w. These features mean that the through hole is not directly exposed to workers or materials where it may become blocked or cause a trip hazard.

An elastic locking member 6 is provided at each joining face of the joining member 2 (or end-cap 3). Correspondingly, an engaging portion 7 a (and related structures) is provided at each joining face of the board member 1. In the embodiments shown in FIGS. 1A-2B, two elastic locking members 6 and corresponding engaging portions 7 a are provided on each joining face, one at each side of the joining member 2 or board member 1 respectively. The female connecting parts 4 and male connecting parts 5 are provided between the two engaging portions 7 a or elastic locking members 6. Providing two locking mechanisms like this means that the board members 1 and joining members 2 (or end-caps 3) are held securely under torsion in a horizontal plane (in a width and length direction) as well as linear forces in a horizontal plane.

It is advantageous that the board members 1, joining members 2 and end-caps 3 can be used independent of their orientation. Therefore, it is preferable that the board members 1, joining members 2 and end-caps 3 have symmetry. It is preferable that the board members 1 and joining members 2 are mirror symmetric in three orthogonal planes, corresponding to planes perpendicular to the length, width and thickness directions. It is preferable that the end-caps are mirror symmetric in two orthogonal planes, corresponding to planes perpendicular to the thickness and width directions. Accordingly, this symmetry applies to each of the features described above. This means that the board members 1, joining members 2 and end-caps are compatible with each other in any orientation.

The board members 1, joining members 2 and end-caps 3 can be made using a number of different materials. As discussed already, certain features of the modular scaffold board make each part suited to certain materials over others.

In some embodiments, the board members 1 have a uniform cross-section. This means that they can be formed by extrusion. Therefore plastic, aluminium, or polymer composites may be preferred. Plastics and polymer composites have the advantage of being more lightweight, which improves productivity, safety and transportation. Further, these materials are not as hard as aluminium so can be more easily drilled so as to form an engaging portion 7 a.

FIGS. 7 to 16 illustrate a second embodiment of a modular scaffold board and it parts. Many features of the second embodiment are similar to those of the first embodiment so the following description focuses on the differences between the embodiments.

FIG. 7A shows a perspective view of a board member 101 of a second embodiment of a modular scaffold board.

In the second embodiment, the joining member is preferably integrally formed with the board member 101. In the preferred arrangement illustrated in the drawings, the joining member comprises a male connecting part 102 at one end of the board member 101 and a female connecting part 104 at the other end of the board member. These male and female parts may have a similar form to the male and female parts described in relation to the first embodiment or may have a slightly different form as illustrated, for example, in FIGS. 7A (and in FIGS. 8 and 11-16).

The second embodiment also has a different form of locking mechanism. The locking mechanism preferably comprises mutually engageable male and female components 106, 107 at respective end of the board member and a separate locking member 112 which is insertable into an aperture 113 in one end of the board member (the ‘female end of the board member in the arrangement shown) and rotatable about an axis perpendicular to a major face of the board member 101 between an unlocked position and a locked position. In the unlocked position it permits the engageable male and female components 106, 107 to engage and disengage from each other and in the locked position it inhibits or prevents disengagement of the male and female components 106, 107.

FIG. 7B shows a perspective view of a locking member 112 used with the board member of FIG. 7A. It has a relatively wide upper end with thumb grips 114 to enable a user to rotate it about its axis, a relatively narrow, waisted section 115 for fitting into an open end of the male component 106 and retaining tabs 116 at its lower end for engaging with the female end of the board member when it is mounted axially within the aperture 113.

FIG. 8A and 8B show a plan view and an end view, respectively, of the board member 101 of FIG. 7A. FIG. 8B shows the male connecting parts 102 of the board member and the male component 106 of the locking mechanism.

FIG. 9A and 9B show a bottom view and an end view (from the other end), respectively, of the board member 101 of FIG. 7A. FIG. 9B shows the female connecting parts 104 of the board member and the female component 107 of the locking mechanism.

FIGS. 10A-10C illustrate assembly of the locking member 112 into the female end of a board member 101.

FIG. 10A shows the locking member 112 ready for insertion into an aperture 113 in a major face of the female end of the board member 101. Preferably, the locking member 112 is a snap-fit into the aperture 113 so once fitted is retained in the aperture. FIG. 10B shows the locking member 112 installed in said aperture 113 in the board member 101, and FIG. 10C is a sectional view of the locking member 112 and board member 101 in this position.

FIGS. 11-13 illustrate operation of the locking mechanism. As the male connecting parts 102 at one end of a first board member 101 are engaged with female connecting parts 104 of another board member (to join the board members together in end-to-end fashion), the male component 106 of the locking mechanism (on the first board member) engages with the female component 107 of the locking mechanism (on the other board member) and the waisted part 115 of the locking member 112 enters an opening 117 at the distal end of the male component 106 of the locking mechanism. The locking member 112 is thus moved from the position shown in FIGS. 11A and 11B to that shown in FIGS. 12A and 12B.

The locking member 112 is then rotated 90 degrees about its axis from the position shown in FIGS. 12A and 12B to that shown in FIGS. 13A and 13B. In this locked position, the width of the waisted portion 115 of the locking member 112 prevents it being withdrawn from the opening 117 in the distal end of the male component 106 of the locking mechanism and thus inhibits or prevents disengagement of the male and female connecting parts 106, 107 of the two board members.

FIG. 11C and 13C show the different widths of the waisted portion 115 of the locking member 112 in the unlocked and locked positions.

FIG. 14A is an exploded perspective view of two board members 101 of the second embodiment prior to being joined together and FIG. 14B is a perspective view of the two board members 101 once they have been joined together (BB the locking member is not shown in these Figures).

As in the first embodiment, end caps are preferably provided for fitting to the two ends of a modular scaffold board. For the preferred version of the second embodiment illustrated in which each board member 101 has a male end and a female end, two versions of end caps will be required, one having male connecting parts for joining to the female connecting parts at one end of the modular board member and the other having female connecting parts for joining to the male connecting parts at the other end of the modular scaffold board.

FIG. 15 is an exploded perspective view of an end cap 103 having male connecting parts 102 ready to be fitted to the female end of a modular scaffold board (again, this Figure does not show the locking member).

A preferred kit of parts for the second embodiment comprises a plurality of boards members 101 including board members of at least two different lengths and a plurality of end caps 103 for fitting to the ends of the modular scaffold boards. Preferably, the kit of parts comprises a plurality of board members 101 of a first length, eg of 1 foot (approx 30 cm) and a plurality of board members 101 of a second length, eg 2 feet (approx 61 cam), together with a plurality of end caps 103 of length (which may also be provided in different lengths, eg 2 inches and 4 inches long (approx 5 cam and 10 cm), whereby modular boards can be assembled in a wide variety of lengths in increments of 2 inches (approx 5 cm).

The need to ‘cut to fit’, which leads to considerable waste in traditional scaffolding, can be minimised or eliminated.

The kit of parts may also comprise a plurality of third board members 101 of a third length, eg 3 feet (approx 91 cm).

In a further arrangement, the kit of parts may also comprise a plurality of fourth board members 101 comprising a male connecting part 102 at one end and a female connecting part 104 at the other end. The fourth board members 101 are typically shorter than the first, second and third board members, and might typically have a length of 4 inches (approx 10 cm).

The male and/or female connecting parts 102, 104 of the fourth board members 101 may also be adapted so that the fourth board member 101 can be connected only between another board member 101 and an end cap 103. This may, for example, be achieved by making the female connecting parts 104 of the fourth board members 101 less deep then the male connecting parts 102 of the first, second and third board members 101 so that these cannot be fully inserted into the female connecting parts 104 of the fourth board members 101. In this case, the end caps 103 with male connecting parts 102 may be provided with shorter male parts 102 so they can be fully inserted into the female connecting parts 104 of the fourth board members 101 (and the female connecting parts 104 of the first, second and third board members)

FIG. 16 is a perspective view of a fourth (shorter) board member of the second embodiment.

It will be appreciated that a shorter board member 101 such as that shown in FIG. 16 may also be regarded as a joining member that joins two longer board members 101 in end-to-end fashion, in effect, in a similar manner to the separate joining member used in the first embodiment (in this case, the shorter board member may have male and female connecting parts of the same length of those of the other board members). A board member 101 such as that shown in FIG. 16 can thus be seen as either a short board member (with integral joining members) for connecting other board members 101 together or as a separate joining member 2 for joining two board members 101 together.

It will also be appreciated that although the joining members of the second embodiment, ie the male joining components 102 thereof, are preferably integrally formed with the remainder of the board member 101, eg in an injection moulding process, it would also be possible for these to be separate parts which have been assembled or joined together (whether reversibly or irreversibly).

It will be appreciated that the modular scaffold boards described herein, eg as shown in FIGS. 1 and 14, have a substantially rectangular cross-section (similar to that of a conventional wooden scaffold board) and, in particular, has substantially planar sides 101A, 101B so that the modular scaffold boards can abut each other side by side without any significant gap there between (but do not need to be connected to be connected to boards positioned alongside).

Although some board members may be designed so they can be used with either face uppermost, it may also be advantageous for them to be designed so as to have an upper face which differs from the lower face, eg to ensure that all locking members are inserted from the upper face, or so that only the upper face need be provided with a non-slip surface finish or because it is desirable for the underside of the board to have a different from for ease of manufacture and/or to reduce the weight of the board member. In one preferred form (not shown) the underside of the board may have an open or concave form), eg as shown in FIGS. 9A and 10C.

As indicated above, the male and female connecting parts 102, 104 are designed to provide a stable connection between board members 101. In particular, it is desirable that the connection is sufficiently strong so that a board member supported only by its connection to other board members at its ends is able to support the weight of a person (or other load bearing requirement for a scaffold board). Thus, whilst the modular scaffold board is still supported by transoms at a minimum specified spacing S, it is not necessary for a transom to be positioned under every board member 101. It will be appreciated that this is of significant importance if one of the length of board members provided, is less than the spacing S.

The shape and design of the male and female connecting parts 102, 104 is critical in determining the strength of the connection they provide. In the embodiments described, the male connecting parts 102 comprise a plurality of fingers, the first embodiment have four fingers side by side 5 and the second embodiment have two pairs of fingers 102A, 102B. A further arrangement (not shown) comprises two sets of three fingers. Other arrangements are possible. A close, snug fit between the male and female connecting parts 102, 104 is also desirable to provide a rigid connection and to minimise any lateral movement, eg in the direction perpendicular to the face of the board members 101. Manufacturing tolerances thus need to be carefully controlled to provide a tight fit. Forming the parts by injection moulding enables the parts to be formed with the required accuracy.

The invention described herein is primarily aimed at providing modular scaffold boards for use in construction of a conventional scaffold structure as distinct from what is known as ‘system’ scaffolding in which bespoke components are used and plank have connectors at their ends for connecting them to some form of framework.

As mentioned, the parts of the modular scaffold board are preferably formed of a plastics material. Plastics and polymer composites also provide materials suitable for other advantageous features of the board members such as colouration so as to identify boards having specific characteristics or textured surfaces to improve grip. Textured surfaces can also be applied to the board members 1 by spray coating. Plastic provides a good base for such a coating. Compared to metals such as aluminium for example, many plastics have better chemical resistance. For example, aluminium will exhibit some powdering due to the formation of aluminium oxide, this can reduce grip. Plastics do not react in this way.

The board members are preferably made from polypropylene block copolymer or polypropylene high impact copolymer. However other plastics may be used, such as PVC, in particular uPVC, PE, in particular HDPE, polyamide nylon and PET. The board members can be further stiffened and/or strengthened by adding reinforcing fibers to the polymer resin so as to form a polymer composite. Reinforcing fibers such as mineral or glass fiber, Kevlar fiber, nylon or rayon may be used.

If the board members, joining members and/or end-caps of the invention are not suitable for forming by extrusion, these parts may be formed by injection molding. Plastics, polymer composites and aluminium are also suitable materials for the joining members and end-caps. The board members, joining members and end-caps may be made from the same material, e.g. polypropylene block copolymer; or from different materials, e.g. polypropylene block copolymer board members and aluminium joining members and end-caps. 

1. A modular scaffold board comprising: a plurality of board members of different lengths; and at least one joining member, joining the board members in an end-to-end fashion.
 2. A modular scaffold board as claimed in claim 1 in which said at least one joining member is a separate component from the board members.
 3. (canceled)
 4. (canceled)
 5. (canceled)
 6. A modular scaffold board as claimed in claim 1 in which each board member has a joining member integrally formed therewith.
 7. A modular scaffold board as claimed in claim 6 in which the joining member comprises a male connecting part at one end of the board member which connects with a female connecting part of another board member.
 8. A modular scaffold board as claimed in claim 6 comprising an end cap at each end thereof.
 9. A modular scaffold board as claimed in claim 8 in which one end cap has a male connecting part connected to a female connecting part of a board member and the other end cap has a female connecting part connected to a male connecting part of another board member.
 10. A kit of parts for providing a modular scaffold board comprising: a plurality of boards members including board members of at least two different lengths and at least one joining member for joining the board members in an end-to-end fashion.
 11. A kit of parts as claimed in claim 10 comprising: a plurality of boards members including board members of at least two different lengths in which the joining member comprises a male connecting part at one end and a female connecting part at the other end integrally formed therewith for joining the board members in an end-to-end fashion.
 12. A kit of parts as claimed in claim 11 comprising a plurality of end caps for fitting to the ends of the modular scaffold board(s).
 13. A kit of parts as claimed in claim 12 comprising a plurality of boards members including board members of at least two different lengths, each board member comprising a male connecting part at one end and a female connecting part at the other end, and a plurality of end caps for fitting to the ends of the modular scaffold board(s).
 14. (canceled)
 15. (canceled)
 16. A kit of parts as claimed in claim 10 comprising a plurality of fourth board members or joining members comprising a male connecting part at one end and a female connecting part at the other end, the male and/or female connecting parts thereof being adapted so that the fourth board member or joining member can be connected only between another board member and an end cap.
 17. A kit of parts in which said fourth board members or joining members have a length of 4 L.
 18. A kit of parts as claimed in claim 17 in which L=1 inch (2.54 cm).
 19. (canceled)
 20. (canceled)
 21. (canceled)
 22. A kit of parts as claimed in claim 1 in which, in use, the male and female connecting parts of the joining member are configured to provide a connection between board members which gives the modular scaffold board stability under forces exerted in a direction perpendicular to the direction of engagement of the male and female connecting parts.
 23. A kit of parts as claimed in claim 22 in which said connection is able to support at least the weight of a person standing thereon whereby, when a modular board is supported by a plurality of transoms spaced apart by a minimum recommended spacing S, board members having a length less than S do not necessarily have to be supported by a transom.
 24. A kit of parts as claimed in claim 1, further comprising a locking mechanism for releasably locking the board members and the joining member in the joined state.
 25. (canceled)
 26. (canceled)
 27. (canceled)
 28. A kit of parts as claimed in claim 1 formed substantially of a plastics material.
 29. A kit of parts as claimed in claim 28 formed by injection moulding.
 30. A method of forming a modular scaffold board, the method comprising the steps of: selecting a plurality of board members from a group of board members including board members of different lengths; and joining the plurality of board members in an end-to-end fashion with at least one joining member.
 31. The method of forming a modular scaffold board according to claim 30, the method further comprising the step of: capping at least one non-joined end of the board members with an end-cap selected from a group of end-caps including end-caps of different lengths.
 32. The method of forming a modular scaffold board according to claim 30 in which the assembled modular scaffold board is arranged to be supported by transoms positioned beneath the board.
 33. The method of forming a modular scaffold board according to claim 30, in which the modular scaffold board is arranged to be used alongside conventional wooden scaffold boards having substantially the same cross-sectional dimensions. 34-42. (canceled) 